US8242040B2 - Process for the removal of corrosion metals from carbonylation catalyst solutions - Google Patents

Process for the removal of corrosion metals from carbonylation catalyst solutions Download PDF

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US8242040B2
US8242040B2 US11/587,339 US58733905A US8242040B2 US 8242040 B2 US8242040 B2 US 8242040B2 US 58733905 A US58733905 A US 58733905A US 8242040 B2 US8242040 B2 US 8242040B2
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carbonylation
process according
resin
catalyst solution
catalyst
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US20070298960A1 (en
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Andrew David Poole
Stephen James Smith
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Ineos Acetyls UK Ltd
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BP Chemicals Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J38/00—Regeneration or reactivation of catalysts, in general
    • B01J38/74—Regeneration or reactivation of catalysts, in general utilising ion-exchange
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J39/00—Cation exchange; Use of material as cation exchangers; Treatment of material for improving the cation exchange properties
    • B01J39/04—Processes using organic exchangers
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/42—Separation; Purification; Stabilisation; Use of additives
    • C07C51/47—Separation; Purification; Stabilisation; Use of additives by solid-liquid treatment; by chemisorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/40—Regeneration or reactivation
    • B01J31/4015—Regeneration or reactivation of catalysts containing metals
    • B01J31/4023—Regeneration or reactivation of catalysts containing metals containing iron group metals, noble metals or copper
    • B01J31/4038—Regeneration or reactivation of catalysts containing metals containing iron group metals, noble metals or copper containing noble metals

Definitions

  • the present invention relates to the removal of corrosion metal contaminants from carbonylation catalyst solutions comprising a carbonylation catalyst such as iridium, rhodium or mixtures thereof.
  • corrosion metal contaminants such as compounds of iron, nickel, molybdenum, chromium and the like form and build up in the carbonylation reaction composition. Such corrosion metal contaminants, if present in sufficient amounts may have an adverse effect on the carbonylation reaction.
  • U.S. Pat. No. 4,007,130 describes a process for regenerating a spent carbonylation catalyst solution comprising a rhodium or iridium catalyst by contacting it with a cation exchange resin in its hydrogen form.
  • EP-A-0 265 140 describes contacting a catalyst solution comprising rhodium, lithium and corrosion metals with a cation exchange resin in its lithium form.
  • PCT patent application, WO 97/15544 describes a process for treating low water content carbonylation catalyst solutions which contain rhodium and an alkali metal to remove metallic corrosion products.
  • the process comprises contacting the catalyst solution with an ion exchange resin and a sufficient amount of water to decrease the concentration of alkali metal ions to optimize removal of corrosion metal products.
  • the carbonylation reaction composition from the reactor is passed to a flash zone for separation into a vapour fraction and a liquid fraction which comprises the majority of the catalyst components.
  • This carbonylation catalyst solution is generally recycled back to the reactor.
  • An iridium or an iridium/rhodium catalysed process is susceptible to small changes in alkali metal concentration and thus increases in the alkali metal concentration is likely to reduce the carbonylation rate and may cause a significant reduction in the rate.
  • a rhodium catalysed process can tolerate greater concentrations of alkali metal however fluctuations in the alkali metal concentration will cause the carbonylation reaction rate to vary resulting in non-steady operation which is both undesirable and uneconomic. It has now been found that by partially loading a cation exchange resin with alkali/alkaline earth metal, the concentration of the alkali/alkaline earth metal in the carbonylation solution can be maintained thereby eliminating or at least mitigating the afore-mentioned disadvantages.
  • the present invention provides a process for the removal of corrosion metal contaminants from a carbonylation catalyst solution comprising a carbonylation catalyst selected from iridium, rhodium and mixtures thereof, an alkali and/or alkaline earth metal and corrosion metal contaminants which process comprises contacting said catalyst solution with a cation exchange resin having its active sites partially loaded with a sufficient amount of alkali and/or alkaline earth metal to maintain the concentration of said alkali and/or alkaline earth metal in the catalyst solution and recovering a catalyst solution of reduced corrosion metal contaminant content.
  • the process of the present invention is particularly applicable to the removal of corrosion metal contaminants from carbonylation catalyst solutions obtained from carbonylation processes employing in the carbonylation reaction composition either an iridium carbonylation catalyst, a rhodium carbonylation catalyst or a combination of iridium and rhodium carbonylation catalysts and also an alkali or alkaline earth metal salt capable of generating iodide ions in-situ.
  • the carbonylation catalyst solution is derived from the liquid phase carbonylation of alcohols and/or reactive derivatives thereof, such as ethers, esters, halides or mixtures thereof to produce carboxylic acids, preferably, acetic acid in the presence of an iridium carbonylation catalyst, a rhodium carbonylation catalyst or a combination of iridium and rhodium carbonylation catalysts, an alkyl halide co-catalyst and an alkali metal or alkaline earth metal salt capable of generating iodide ions in-situ such as an alkali metal or alkaline earth metal iodide or an alkali metal or alkaline earth metal acetate.
  • a catalyst promoter such as ruthenium, rhenium or osmium may also be present in the carbonylation reaction composition.
  • the carbonylation catalyst solution may be obtained from the liquid phase carbonylation of alcohols and/or reactive derivatives thereof in the presence of a rhodium catalyst and an alkali/alkaline earth metal salt capable of generating iodide ions in-situ under substantially anhydrous conditions to produce a carboxylic anhydride such as acetic anhydride or a mixture of a carboxylic anhydride and a carboxylic acid such as a mixture of acetic anhydride and acetic acid.
  • a carboxylic anhydride such as acetic anhydride or a mixture of a carboxylic anhydride and a carboxylic acid such as a mixture of acetic anhydride and acetic acid.
  • the carbonylation catalyst solution to be treated by the process of the present invention comprises an iridium carbonylation catalyst, a rhodium carbonylation catalyst or a mixture thereof.
  • Suitable iridium carbonylation catalysts are described, for example in EP-A-0 643 034 and EP 0 752 406.
  • Suitable rhodium carbonylation catalysts are described, for example, in EP-A-0 161 874 and U.S. Pat. No. 6,211,405.
  • the catalyst solution treated in the process of the present invention comprises an iridium carbonylation catalyst
  • the catalyst solution may further comprise one or more catalyst promoters.
  • Suitable promoters are selected from ruthenium, osmium and rhenium, and are more preferably selected from ruthenium and osmium. Ruthenium is the most preferred promoter. Examples of suitable promoters are described, for example, in EP-A-0 643 034 and EP 0 752 406.
  • the carbonylation reaction composition comprises a source of alkali metal and/or alkaline earth metal such as salts capable of generating iodide ions in-situ.
  • Suitable salts include alkali metal or alkaline earth metal iodides and alkali metal or alkaline earth metal acetates.
  • the alkali metal salt is lithium iodide, lithium acetate, sodium iodide or sodium acetate.
  • Suitable alkaline earth metal salts are the iodides or acetates of calcium or magnesium.
  • the carbonylation catalyst solution may also comprise unconverted carbonylation reactant, for example alcohols, ethers, halides or mixtures thereof.
  • the reactant may comprise C 1 to C 10 alcohols, such as methanol; dialkyl ethers wherein the alkyl groups independently have 1 to 10 carbon atoms, for example dimethyl ether; alkyl halides having 1 to 10 carbon atoms such as methyl iodide and esters of C 1 to C 10 alcohols with C 2 to C 11 carboxylic acids, for example, methyl acetate.
  • carboxylic acids water is required as co-reactant for ether or ester reactants.
  • methanol and/or methyl acetate are used as reactants.
  • the carbonylation catalyst solution treated in the process of the present invention may also comprise an alkyl halide co-catalyst such as methyl iodide.
  • the concentration of the alkyl halide co-catalyst, such as methyl iodide, in the liquid carbonylation reaction composition is in the range 1 to 20% by weight, preferably 2 to 16% by weight.
  • the carbonylation catalyst solution may comprise a solvent compatible with the carbonylation process from which the catalyst solution is derived and which is also compatible with the cation exchange resin.
  • the solvent may be acetic acid.
  • the catalyst solution may also comprise water.
  • Water may be formed in situ in the carbonylation reaction composition, for example, by the esterification reaction between methanol reactant and acetic acid product.
  • the concentration of water in process streams containing catalyst system for recycle to the carbonylation reaction zones is preferably maintained at a concentration of at least 0.5% by weight.
  • the carboxylic acid may comprise a carboxylic acid having 1 to 10 carbon atoms and is preferably acetic acid.
  • carbonylation processes operate at 100-300° C. and at elevated pressure (15 to 200 barg) with a partial pressure of carbon monoxide of 2-30 atmospheres and may be carried out in one or more reaction zones.
  • the process of the present invention is particularly applicable to the removal of corrosion metal contaminants from a carbonylation catalyst solution comprising an iridium carbonylation catalyst, methyl iodide co-catalyst, water, acetic acid, methyl acetate, at least one promoter selected from ruthenium, osmium and rhenium and an alkali and/or alkaline earth metal.
  • the cation exchange resins suitable for use in the process of the present invention may be either of the strong-acid or the weak-acid type in the alkali or alkaline earth metal form. Any alkali metal or alkaline earth metal cation is acceptable provided the corresponding alkali metal or alkaline earth metal cation is employed in the alkali metal or alkaline earth metal salt capable of generating iodide ions.
  • a cation exchange resin in its lithium, sodium, calcium or magnesium form is employed.
  • the strong-acid type resin may be a sulphonated styrene-divinylbenzene copolymer or a phenol-formaldehyde condensation polymer.
  • the weak-acid type resin may be a copolymer of acrylic or methacrylic acid or esters or the corresponding nitrites or a phenolic resin.
  • the cation exchange resin for use in the present invention is a strong-acid type resin.
  • the resin may be either a macroreticular type resin or a gel-type resin.
  • the cation exchange resin may be converted to its alkali/alkaline earth metal form by contacting the resin with a solution of an alkali/alkaline earth metal salt, such as a solution of alkali metal acetate or iodide, for example lithium or sodium acetate or lithium or sodium iodide or a solution of the iodides or acetates of an alkaline earth metal such as the acetates or iodides of magnesium or calcium. Suitable procedures are well known in the art.
  • the amount of alkali metal or alkaline earth metal salt added to the resin should be such that the loaded resin has greater than 0 but less than 100% of its active sites loaded with the alkali metal and/or alkaline earth metal.
  • the exact degree of loading onto the resin required to maintain the concentration of alkali/alkaline earth metal in the catalyst solution will depend on the amount of alkali/alkaline earth metal employed in the carbonylation reaction solution, the specific alkali metal or alkaline earth metal to be loaded onto the resin because different metals will have a different degree of affinity for a resin, the flowrate through the resin bed and the operating temperature of the resin bed.
  • the resin suitably has >0 to 60% of its active sites loaded with lithium ions, such as 30 to 55% of its active sites.
  • the resin suitably has >0 to 60% of its active sites loaded with sodium ions, such as 30 to 55% of its active sites.
  • the contacting of the cation exchange resin in its alkali metal or alkaline earth metal form with the carbonylation catalyst solution may be carried out using any suitable conventional procedure and equipment.
  • the carbonylation catalyst solution is passed through a fixed-bed of the resin.
  • the rate of flow of the catalyst solution through the fixed-bed of resin during the corrosion metal removal process will, in general, be that recommended by the resin manufacturer and may typically be up to about 20 bed volumes per hour.
  • the contacting of the carbonylation catalyst solution with the cation exchange resin in its alkali/alkaline earth metal form may be carried out at any suitable temperature above the freezing point of the catalyst solution and below the temperature at which the resin and/or the catalyst solution exhibits undesirable decomposition. If temperatures above the boiling point of the catalyst solution are employed, then the contacting should be carried out under pressure to maintain the catalyst solution in the liquid phase.
  • the contacting temperature may be in the range 0° to 110° C. such as 10° to 100° C.
  • pressure is not a critical variable.
  • the contacting operation may be carried out at atmospheric pressure or a pressure slightly above atmospheric but superatmospheric or sub-atmospheric pressures may be employed if desired.
  • the cation exchange resin in its alkali metal or alkaline earth metal form When the cation exchange resin in its alkali metal or alkaline earth metal form has reached its capacity for corrosion metal contaminants it may firstly be rinsed with a liquid compatible with carbonylation processes, for example, carboxylic acid to remove residual carbonylation catalyst solution and then regenerated.
  • the cation exchange resin may be regenerated by the methods recommended by the manufacturers to displace the retained corrosion metal contaminants.
  • a solution of carboxylic acid such as acetic acid and alkali metal or alkaline earth metal acetate, such as lithium acetate, sodium acetate or magnesium acetate may be used to regenerate the resin.
  • the corrosion metal contaminant removal process of the present invention may be operated as a batch or as a continuous process, preferably, as a continuous process.
  • more than one resin bed is provided so that whilst the carbonylation catalyst solution is being passed through one resin bed, one or more other resin beds are being regenerated.
  • the process of the present invention is particularly applicable to the removal of corrosion metal contaminants such as iron, nickel, chromium, manganese and molybdenum, preferably, iron and nickel.
  • Each corrosion metal contaminant may be present in the carbonylation reaction composition in an amount up to its limit of solubility. Typically, this may be up to 10,000 ppm by weight of metal.
  • the amount of each corrosion metal removed from the catalyst solution will depend upon the initial concentration of the corrosion metal, the degree of alkali metal or alkaline earth metal loading on the resin, the capacity of the resin, and operating conditions such as flow rate of the catalyst solution, reactor composition and temperature of the resin bed.
  • a liquid-phase carbonylation reaction is generally carried out in one or more reaction zones.
  • the carbonylation reaction is the carbonylation of methanol and/or a reactive derivative thereof and is carried out in the presence of an iridium and/or rhodium carbonylation catalyst, an alkali metal salt capable of generating iodide ions, methyl iodide co-catalyst and optionally a promoter, and a finite concentration of water
  • the product will be acetic acid.
  • the crude acetic acid product may be recovered from a reaction zone by flash separation.
  • flash separation the carbonylation reaction composition is passed to a flashing zone via a flashing valve.
  • the flash separation zone may be an adiabatic flash vessel or may have additional heating means.
  • the carbonylation catalyst solution comprising the majority of the catalyst and, if employed, the majority of the promoter, is separated from a vapour fraction comprising acetic acid, carbonylatable reactant, water and methyl iodide co-catalyst and non-condensable gases such as nitrogen, carbon monoxide, hydrogen and carbon dioxide; at least a portion of the carbonylation catalyst solution is recycled to the reaction zone and the vapour fraction is passed to one or more purification stages as desired to recover acetic acid product.
  • the build-up of corrosion metal contaminants in the carbonylation reaction composition can be reduced.
  • a slipstream of catalyst solution is removed from the flash separation zone and treated according to the process of the present invention to remove corrosion metal contaminants and provide a catalyst solution having reduced corrosion metal contaminants which is recycled to the carbonylation reactor.
  • FIG. 1 are plots of lithium concentration versus Hours bed on stream
  • FIG. 2 is a plot of sodium concentration versus Hours bed on stream.
  • Lithium acetate solution prepared by adding 460 g LiOAc.2H 2 O to 2.5 kg (95/5 wt % acetic acid/water solution) was passed through a bed containing 500 ml of pre-soaked Amberlyst 15 at a liquid hour space velocity (LHSV) of 4 h ⁇ 1 . The resin was then washed with water and oven-dried at 100° C. for 24 hours. The loaded resin contained 2.6 wt % Li. Resins loaded with 0%, 25%, 50%, 75% and 100% lithium were prepared by mixing together appropriate amounts of the 2.6 wt % lithium loaded resin with unloaded Amberlyst 15.
  • Preparation method 1 was repeated except that a magnesium acetate solution (480 g Mg(OAc) 2 in 2.7 kg 95/5 wt % acetic acid/water solution) was used to load the resin.
  • the loaded resin contained 4.4 wt % Mg.
  • Resins loaded with 0%, 25%, 50%, 75% and 100% magnesium were prepared by mixing together appropriate amounts of the 4.4 wt % magnesium loaded resin with unloaded Amberlyst 15.
  • a carbonylation solution was prepared by mixing 17.2 kg acetic acid, 1.0 kg water, 1.6 kg methyl acetate, 200 g iodomethane, 1.9 g iron acetate, 2.6 g nickel acetate and 11.1 g lithium acetate.
  • the solution was pumped at 1.0 l.h ⁇ 1 through a bed containing 100 ml of resin. Samples were taken after 2, 4, 6, 8 and 10 bed volumes of feed had passed through the bed and analysed for Li, Fe and Ni content.
  • the initial concentration of Li and the corrosion metals and the results of the Examples are given in Table 1.
  • Example 12 cation exchange resin having 50% of its active sites loaded with lithium was prepared according to Preparation Method 1 above.
  • Example 11 the same type of resin was used but with no lithium loading (that is in its proton form).
  • a catalyst solution obtained from the flash zone of an acetic acid reaction system comprising acetic acid, iridium, methyl iodide, methyl acetate, lithium, corrosion metals and water was passed through a 30 ml volume of each resin bed at a flow rate of 300 ml h ⁇ 1 .
  • the effect of the resin beds on the lithium concentration in the reactor are shown in FIG. 1 .
  • FIG. 1 clearly shows that for the comparison resin (Ex. 11) the concentration of lithium in the reactor became significantly depleted after 100 hours and lithium had to be added.
  • use of the partially loaded resin resulted in virtually no net change in the reactor lithium concentration.
  • a 50:50 mixture of Amberjet 1500 and Amberjet 1200Na (both strong acid gel type resins commercially available from Rohm & Haas; Amberjet 1200Na having sodium on the active sites) was prepared.
  • a catalyst solution obtained from the flash zone of an acetic acid reaction system comprising acetic acid, iridium, methyl iodide, methyl acetate, sodium, corrosion metals and water was passed through a 30 ml volume of the resin bed at a flow rate of 300 ml h ⁇ 1 .
  • FIG. 2 illustrates that a cation exchange resin partially loaded with sodium does not significantly alter the sodium concentration in the reactor.

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US11/587,339 2004-05-07 2005-03-31 Process for the removal of corrosion metals from carbonylation catalyst solutions Active US8242040B2 (en)

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GBGB0410289.3A GB0410289D0 (en) 2004-05-07 2004-05-07 Process
GB0410289.3 2004-05-07
PCT/GB2005/001216 WO2005107945A1 (en) 2004-05-07 2005-03-31 Process for the removal of corrosion metals from carbonylation catalyst solutions

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EP (1) EP1742739A1 (zh)
JP (1) JP4856629B2 (zh)
KR (1) KR101132996B1 (zh)
CN (1) CN100479922C (zh)
CA (1) CA2562698C (zh)
GB (1) GB0410289D0 (zh)
MY (1) MY146270A (zh)
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Cited By (1)

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WO2016077672A1 (en) * 2014-11-14 2016-05-19 Celanese International Corporation Processes for improving acetic acid yield by removing iron

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EP2075070A1 (en) * 2007-12-13 2009-07-01 BP Chemicals Limited Catalyst recovery process
CN102112418B (zh) * 2008-07-30 2013-11-13 旭化成化学株式会社 环烯烃的制造方法和制造装置
EP2658903B1 (en) * 2010-12-30 2017-02-08 Celanese International Corporation Ion exchange resin composition for the purification of acetic acid product streams
US8697908B2 (en) * 2011-05-05 2014-04-15 Celanese International Corporation Removal of amine compounds from carbonylation process stream containing corrosion metal contaminants
US10067113B2 (en) 2014-02-28 2018-09-04 LyondellBasell Acetyis, LLC Acetic acid production process
WO2016209927A1 (en) 2015-06-23 2016-12-29 Lyondellbasell Acetyls, Llc Silver loaded halide removal resins for treating halide containing solutions
JP6786308B2 (ja) * 2016-08-30 2020-11-18 月島環境エンジニアリング株式会社 陽イオン交換樹脂の再生方法、被処理液の処理方法及び陽イオン交換樹脂を含む処理設備
CN107141213A (zh) * 2017-05-24 2017-09-08 北京三聚环保新材料股份有限公司 一种甲醇羰基化合成醋酸的方法
CN110078612B (zh) * 2019-06-06 2021-09-07 上海华谊（集团）公司 催化剂循环液的纯化方法

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EP0265140A1 (en) 1986-10-14 1988-04-27 Hoechst Celanese Corporation Process for regenerating a carbonylation catalyst solution to remove corrosion metals
US5124290A (en) * 1990-10-30 1992-06-23 Hoechst Aktiengesellschaft Process for removing metallic corrosion products from carbonylation reactions carried out under anhydrous conditions
EP0538040A2 (en) 1991-10-18 1993-04-21 BP Chemicals Limited Process for removing iodide compounds from carboxylic acids and carboxylic acid anhydrides
EP0618185A1 (en) 1993-03-22 1994-10-05 BP Chemicals Limited Process for the removal of corrosion metal contaminants from liquid compositions
JPH06340574A (ja) 1993-03-31 1994-12-13 Rhone Poulenc Chim ロジウム及びイリジウムを基とする触媒の存在下でカルボン酸又は対応するエステルを製造する方法
GB2298200A (en) 1995-02-21 1996-08-28 Bp Chem Int Ltd Catalyst system comprising iridium and rhodium catalyst, alkyl halide and at least one ruthenium, osmium or rhenium promoter for use in alcohol carbonylation
WO1997015544A1 (en) 1995-10-27 1997-05-01 Hoechst Celanese Corporation Process for improving productivity of a carbonylation catalyst solution by removing corrosion metals
US20050079122A1 (en) * 2003-10-10 2005-04-14 Dimascio Felice Systems and methods for generating chlorine dioxide

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EP0618185A1 (en) 1993-03-22 1994-10-05 BP Chemicals Limited Process for the removal of corrosion metal contaminants from liquid compositions
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016077672A1 (en) * 2014-11-14 2016-05-19 Celanese International Corporation Processes for improving acetic acid yield by removing iron
US9688600B2 (en) 2014-11-14 2017-06-27 Celanese International Corporation Processes for improving acetic acid yield by removing iron

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RU2381836C2 (ru) 2010-02-20
WO2005107945A1 (en) 2005-11-17
KR101132996B1 (ko) 2012-04-09
CA2562698A1 (en) 2005-11-17
KR20070009669A (ko) 2007-01-18
MY146270A (en) 2012-07-31
US20070298960A1 (en) 2007-12-27
CN100479922C (zh) 2009-04-22
UA92320C2 (en) 2010-10-25
EP1742739A1 (en) 2007-01-17
RU2006143154A (ru) 2008-06-20
JP4856629B2 (ja) 2012-01-18
JP2007536082A (ja) 2007-12-13
CN1950148A (zh) 2007-04-18
CA2562698C (en) 2013-06-04
RS20060615A (en) 2008-06-05

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